COST AND PERFORMANCE BENEFITS OF DUAL LAMINATE PIPE OVER LINED STEEL

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1 COST AND PERFORMANCE BENEFITS OF DUAL LAMINATE PIPE OVER LINED STEEL Kira Townsend Sales and Business Development Manager RPS Composites Inc. Mobile, AL Prepared for Clearwater th Annual International Phosphate Fertilizer & Sulfuric Acid Technology Conference April 2016

2 COST AND PERFORMANCE BENEFITS OF DUAL LAMINATE PIPE OVER LINED STEEL Plastic lined steel is commonly utilized in chemical processing applications for demanding service. This paper will explore dual laminate composite piping as an alternative to lined steel. The cost, performance, and safety benefits will be presented of dual laminate piping systems over lined steel pipe. INTRODUCTION Thermoplastic materials such as olefins, vinyls, and fluoropolymers offer excellent corrosion resistance to severe service environments such as acid, bleach, solvent, and chlorides. They can be used as materials of construction for piping but are also commonly utilized as a liner inside steel piping. The plastic provides the line of defense for the service environment and the steel provides pressure resistance, structural integrity, and rigidity for the piping system. Another alternative to steel as the outer casing is to use fiberglass reinforced plastic (FRP) for pressure resistance and structural integrity of the piping, fittings, and flanges. Plastic lined FRP is referred to as Dual Laminate and it provides a lighter weight version of the Lined Steel product and it is non-conductive, and non-corrosive. It can be provided as flanged, minimally flanged, and Flange-less. The process of manufacturing the Dual Laminate piping includes a bonding layer between the thermoplastic liner and the thermoset FRP structure, resulting in a solid wall that can absorb the thermal expansion and operating stresses involved with a given piping system. The thermoset resin based structure will have an expansion rate of approximately 2.5 times that of steel, so a pipe stress analysis is regularly performed for Dual Laminate piping systems. This paper will explore Dual Laminate piping for severe chemical service with an emphasis on the Pipe Stress Analysis process and a Case Study where Dual Laminate piping was installed in lieu of Lined Steel. COMPARISON OF DUAL LAMINATES TO LINED STEEL Plastic lined equipment is often utilized for severe service such as Chlorine, Sodium Hypochlorite, Sodium Hydroxide (high temp), Hydrochloric acid (35-37% at high temp), Sulfuric acid (92 to 98% conc.), and Organic compounds. The commonly available liners for both Lined Steel and Dual Laminates include three classifications: Vinyls (PVC, CPVC) 1

3 Olefins (Polypropylene, HDPE) Fluoropolymers (ETFE, ECTFE, PVDF, PTFE, FEP, PFA) In Dual Laminate equipment, the liner is bonded to the structure whereas Lined Steel is provided with a loose fit or swaged liner. The presence of a bonded liner reduces the risk of mechanical damage because of the ability to distribute the concentration of stresses. The bonded liner also prevents liner collapse when vacuum conditions exist. An annular space exists in lined steel equipment between the liner and the metal casing and condensate from permeation can accumulate in this cavity. Vent or weep holes are installed in the steel pipe to allow for removal of the permeated vapor. Because the dual laminate pipe is made with a bonded liner, there is no need for weep holes. Corrosion of the steel casing is often seen at the area of the weep holes and at the flanges, but with a chemically resistant FRP structure and no weep holes, the exterior and flanges of Dual Laminate will not corrode. Exterior corrosion from fumes or splashing can also attack the steel casing in Lined Steel, but the FRP exterior of Dual Laminates is supplied with a top coat which is corrosion resistant, UV inhibitive, and pigmented for easy identification. The most commonly used lining materials for managing severe service are the fully fluorinated materials such as FEP and PTFE. These have a high temperature rating and are resistant to a wide range of chemical streams. Of the fully fluorinated polymers, FEP is a commonly utilized liner for FRP, and PTFE is supplied regularly in metallic piping. 2

4 CONSTRUCTION METHODS OF DUAL LAMINATES Lined Steel pipe and fittings are supplied with all flanged ends and built to standard ANSI dimensions, with the pipe built in any length up to 20 ft. When the system is installed, all joints are flanged connections which are potential leak points and source for fugitive emissions. End users will often install flange protectors which is an added expense to the system. Dual Laminate piping systems are also supplied in ANSI fanged configurations but can also be customized for other installation options. In addition to flanged components, Dual Laminate piping can be supplied as minimally flanged and as Flange-less. Flanged All spools and fittings are flanged according to ANSI dimensions and specifications. Minimally Flanged This approach replaces 40 to 60% of the flanges with shop joints and utilizes flanges at the field joints only. By reducing flanges, bolts, nuts, gaskets, flange protectors, and the field labor required to install flanged connections, a cost savings is realized. Further, the system has fewer points of fugitive emissions and leaks which are inherent to flanged connections. Flange-Less This construction eliminates all flanges with exception of connections at valves, instrumentation, etc. The piping is shop assembled to the furthest degree and then the remaining welds are performed in the field by certified bonders from the factory. All three systems provide various advantages for installation depending on client needs and preferences. Following is a comparison of a conventionally flanged spool vs. minimally flanged. 3

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6 COST When comparing the cost of dual laminate piping to lined steel it is found that flanged fittings made with the dual laminate construction are more expensive, however piping is comparable pricewise at 4 diameter and larger. Cost benefits are found primarily when a minimally flanged or Flange-Less approach is taken. The elimination of flanges and their associated costs provides a significant cost savings over the project scope. Other savings are realized by the low maintenance cost and improved reliability/safety associated with Dual Laminate piping systems over Lined Steel. CASE HISTORY A case history is provided which will detail how Dual Laminate piping was used at a major chemical processor to transfer Hydrochloric Acid from the rail car unloading area to the storage tanks for processing. While improving safety and productivity, and streamlining the supply process of their major feedstock were this company s primary goals, they also succeeded in coming in below budget. Their success can be attributed to the use of a Flange-Less Dual Laminate piping system for the transfer of HCl to the tanks. Background The chemical processor frequently received truck trailer loads of Hydrochloric Acid which was transferred into four storage tanks. Their operation was vulnerable to bad weather and road closures which could hinder their receipt of the acid. Railroad tracks existed on the other side of the building from the storage tanks and it was feasible 5

7 for the HCl to be supplied by rail car to the site. This would reduce the number of deliveries since rail cars have four times the capacity of a truck trailer. Also, the railroad would be less prone to weather delays. A new pipe line from the railcar unloading area to the tanks would need to be established and the company initially felt that plastic lined steel was the best material of construction for the line. The straight route connecting the two areas traveled 300 ft. over a wooden roof. The alternate route was 550 ft. around the building perimeter. A lined steel system over the roof would have 15 flanged connections which would require protection and a dual containment system. The routing of pipe around the building would require the installation of a new support system around the perimeter and the use of flange protectors. The use of dual laminate pipe was evaluated and it was realized that the Flange-Less approach to supplying the pipe system would allow the line to be routed over the building without a containment system or flanged protectors. The chosen Flange-Less piping system was the fully fluorinated liner FEP inside an FRP structural wall (FEP/FRP). 6

8 Solution The choice of FEP/FRP with the elimination of all flanges over the roof provided a solution that was lightweight, corrosion resistant inside and out, color coded, and it removed all potential for leaks. The pipe would be factory prefabricated into spools to the furthest degree for shipment. The successful complete installation would be dependent on the use of qualified bonders and close attention to system layout and support design/installation. An integral part of the pipe installation was the performance of a Pipe Stress Analysis (PSA) which will be detailed in this paper. Pipe Stress Analysis (PSA) The analysis of piping under pressure, weight and thermal expansion is complex. Pipe stress analysis is a process which is directly interrelated to the piping layout and support design. The layout of the piping system should be executed with the requirements of piping stress and pipe supports in mind. This includes: Sufficient flexibility for thermal expansion; 7

9 Proper pipe routing so that simple and economical pipe supports can be constructed Selection of piping materials and section properties commensurate with the intended service, temperatures, pressures, and anticipated loadings. Once the piping layout is finalized, the details of the piping support system must be determined. Possible support locations and types must be iterated until all stress requirements are satisfied. Analysis of this type is most often undertaken using a design program such as CAESAR II. CAESAR II enables the designer to assemble data from the design to construct detailed analysis models. In addition to evaluating a piping system's load capabilities, this pipe stress analysis software has other functions: Analyze response to deadweight, thermal, and pressure loads. Measure the effects of support settlement, wave and seismic loads, and wind. Define loads for proper selection of pipe supports. The analysis of the HCl piping for this project began with field measurements of the proposed routing. This information was converted into manufacturing drawings which were then used to convey to the customer what would be built, and also providing sufficient information to Manufacturing to produce the required components, and providing detailed information for field installation crews. The PSA analyst utilized the manufacturing drawings along with material properties of the pipe, system loads, and proposed support locations, and entered that data into the PSA software. In conjunction with the data entry, a system drawing called a node map, was generated. The node map identifies the locations of each node in the system. Nodes are defined points in the geometry at which the PSA software will report output data. At a minimum, nodes are placed at each change of direction and each support. Due to this system having a relatively low operating temperature and long runs of straight pipe it was expected to display relatively low stresses for the FEP/FRP piping. It was therefore not difficult to arrive at an acceptable support system design. Each end of the long straight run was anchored in place and then guided at appropriate intervals to eliminate the chance of the pipe buckling. The B31.3 Piping Code provides guidance for design and analysis of FRP piping systems. Prior to running the analysis, the PSA analyst defined a set of load case combinations based on the requirements of ASME B31.3. These included: Dead loads Pressure Thermal loads Wind loads 8

10 Seismic loads The output from the PSA is a node list for each load case that details the stresses, deflections, and support loads. The analysis provided a node by node comparison of the calculated stresses and the code allowable stresses. Adjustments were made in the geometry of the piping system and the pipe supports to modify the calculated stresses to be less than the Code allowable stress at every node. The changes in the system geometry were referred back to the designer to adjust and finalize the manufacturing and field installation drawings. Project Results The project was considered a success by the customer due to the safety improvements associated with the material choice. Flanged connections over the roof were avoided, a color coded UV resistant exterior coating provided easy identification of the line for safety training, the low weight of the piping system minimized the additional load on the roof, and eliminated the truck deliveries reduced the traffic to the site. From a cost standpoint, the cost of the FEP/FRP Dual Laminate system, including Pipe Stress Analysis and installation was 25% less than the estimated cost of the lined steel piping. The reduced maintenance due to the longer life expectancy and exterior corrosion resistance will continue to provide savings on an O&M basis. CONCLUSION In summary, many benefits exist in using Dual Laminate over Lined Steel in chemical processing applications. These include a lower upfront and O&M cost, customization available to reduce flanged connections, inherent exterior and interior corrosion resistance, and a bonded liner which will resist vacuum and thermal stresses. Overall the Cost, Performance, and Safety benefits of Dual Laminate over lined steel pipe make it an excellent alternative for handling corrosive service in the Chemical Processing Industry. 9

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